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WRITE-UP

ON

AUTOMATIC TURBINE RUNUP SYSTEM

(MAX DNA BASED)

PROJECT : 2X250 MW DVC MEJIA TPS UNIT 5&6

CUSTOMER : DVC

00 20.11.04 SCVSd./ BSR Sd./ MRB Sd./

Rev Date Remark Prepared. Checked Approved

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1.0 INTRODUCTION :

A successful start-up of the turbine normally requires acquisition, analysis and

collation of a wide variety of information pertaining to various parameters like oil
pressure, vacuum, temperature, speed etc. Apart from this it is important to
know the status of the auxiliary equipment. It is an arduous task for the
operator to handle and collate so many bits of information, swiftly and correctly. A
microprocessor based automatic run-up system performs this task swiftly,
accurately and at an appropriate time. The chances of mal-operation due to
human error in judgement of the situations, get practically eliminated.

2.0 CONCEPT :

The Programmable Automatic Turbine Run-up System (ATRS) is based on the

'Functional Group Control' philosophy. The control area is divided into clearly
defined functional areas called 'Functional Groups'. Each functional group is
organised and hierarchically arranged in Sub-Group Control (SGC), Sub-Loop
Control (SLC) and Drive Interface Function .

Each functional group is realised in a Remote Processing Unit (RPU) which houses
the Distributed Processing Unit (DPU), Input/output modules and the
Communication Network. DPU is the process controller which executes control
algorithms, sequence logic and data acquisition functions. Remote Processing Units
(RPU) are connected to each other and operator workstations (OWS) through
maxNET an ethernet communication network. The modules in a RPU communicate
with each other through a I/O bus.

2.1 SUB-GROUP CONTROL :

SGC executes commands to bring the equipment upto a particular defined status.
The commands are executed in a predefined sequence in the form of steps.
Desired number of criteria act as preconditions before the SGC can take off or
execute its defined sequence. The functional group continues to function
automatically all the time demanding enabling criteria based on the process
requirements and from other FGs, if required. In case the desired criteria is not
available, the system would automatically act in such a manner as to ensure the
safety of the main equipment.

The sequence is programmed in the processor. The process signals are acquired
through the input modules and are available on the bus.

For each step there is a waiting time and a monitoring time which are defined
below:

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Waiting Time : It implies that the subsequent step will not be executed unless the
specified time elapses. If no waiting time is specified, the next step gets executed
as soon as the enabling criteria are fulfilled.

Monitoring Time : It is the time required for executing the command of any step
as well as the time required for appearance of criteria for the next step. Under
healthy conditions it should happen within the specified time, otherwise an alarm
is initiated. Whenever there is uncertainty regarding the time required for
completing a particular task, such as warming-up, pulling vacuum etc., the
monitoring time is blocked.

ATRS can be switched on at any stage after completing certain tasks manually, if
so desired. In such cases, the SGC program quickly scans through the steps and
starts executing from the stage upto which the tasks have been completed
manually. This is achieved by incorporating suitable overflow /bypass conditions
in the logic.

SGC issues commands either to the SLC or directly to the drive through I/O
modules.

ATRS is organised in the following three Sub-Groups :

! Oil supply
! Evacuation
! Turbine

Each of these SGCs has its subordinate SLCs and drive interface function These
SGCs in conjunction with the turbine governing system , Turbine Stress Evaluator
and the auto-synchroniser accomplish the function of start-up of the TG set.

2.1.1 Controls & Displays Available To Operator In A SGC :

Each subgroup control can be switched on and off from the operator workstation
(OWS) . The 'Startup' and 'Shutdown' program can also be started manually from
there.

The control display as shown in Fig-1 with standardised functions is provided on

the operator workstation (OWS) for manual operations and indications of the
sub-group control.

In case of auto-mode, control button 2 needs to be clicked upon for starting the
program in 'operation' i.e. 'Startup' direction while click button 1 needs to be
clicked upon for initiating the shutdown program. Steady light would appear in
indication button 4 & 5 when the desired and defined status of mechanical
equipment is achieved.

Indication Button 4 or 5 rapidly flashing, indicates that the program is running

towards the desired status and there is no fault.

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Indication Button 4 or 5 slowly flashing, indicates that the program is in the

desired mode but a fault has appeared somewhere.

Steady indication in any of the indication buttons of step display indicates the step
number in which the program exists in any given moment. Steady indication in
step indication buttons and slow flashing indication in indication button 4 or 5
indicates that the program is stuck and there would also be steady indication in
criterion indication buttons indicating which criterion has not been fulfilled.

2.1.2 Method Of Representation & Other Features:

a. In the logic diagram, the group control multifunction of subgroup control (SGC)
is schematically represented as shown in Fig-2.1.

b. A typical step of subgroup control is represented as shown in Fig-2.2.

c. The steps for 'Startup' program are enumerated from 1 to 50 while the steps
for 'Shutdown' program are enumerated from 51 to 99.

d. The signals hooked with protection channel 'P' have the highest priority and
execute the logic even without seeking the availability of 'Release Criteria'.

2.2 SUB-LOOP CONTROL (SLC) :

A SLC, when switched on, actuates the equipment and brings it to the desired
status as demanded by the process and there is no sequence logic involved in it.
In other words, SLC is like a watch-dog performing an assigned duty. All
mechanical equipment which need to be switched on/off based on process
consideration are hooked-up in various SLCs. Standby equipment is also
interlocked in SLCs.

SLC can be switched on either manually or through SGC and issues commands to
the drive through I/O modules.

SLC logic is also realised in the DPU .

2.2.1 Controls & Displays Available To Operator In A SLC:

The control display with standardised functions is provided in the operator

workstation (OWS) for manual operation and indication of the subloop control. Fig-
3 indicates the control display for SLC.

2.3 DRIVE INTERFACE :

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Each remote controlled drive has a drive interface software block which acts as a
standard interface between the command transmitters and receivers in the plant
and undertakes all necessary signal processing and monitoring.

The drive interface block receives manual commands from the OWS through Input
modules active protection signals and enabling signals from the protective logic,
as well as automatic control commands from the SGC/SLC. It interlocks the input
commands according to their priority and validity and then passes actuation
signals to drive through the output modules. The status checkbacks received from
the switchgear or actuators are acquired through input modules, processed and
transmitted to OWS, the protective logic and the SGC.The interposing relays for
interfacing with switchgear are also housed in the control panels.

2.3.1 Control displays with standardised functions are provided on the OWS for
manual control and checkback of the drives. A typical control display is
indicated in Fig-4.1.

2.3.2 In the logic diagram, the control interface module is represented as shown in Fig
4.2.

2.3.3 For certain critical drives hardwired back up control tiles are provided on the control
desk for operator interface.

3.0 MAXNET (Ethernet network) :

The MAXNET is the redundant ethernet network used for communication between
the various RPUs as the part of the Turbine control system and the operator
workstations allowing global access to all plant data. The maxNET Network consists
of two completely independent ethernet networks to ensure maximum availability
and fault tolerance.The network provides redundant communication networks with
no single point of failure which can affect more than one station. The TCP/IP
protocol is used for network communication .Switched hubs used in the maxNET
network provide 100Mbps full duplex communication between switches, while
network speed from switched hub to RPU and maxSTATION is 10Mbps.Switched hub
enhance network performance and improve the network security.

4.0 MAX STATION SYSTEM:

The maxSTATION is the Man Machine Interface system for the MAX 1000+PLUS ,
Distributed Control System.It is a computer-based system with configurator,
graphic displays data management software and associated hardware. It consists
of operator's workstation and Engineer's workstation.

The operators workstation provides interface to the process with standard and
custom displays. The control commands are issued by the operator to the drive
interface through video Display Unit (VDU) and Keyboard (KBD) which are part
of maxSTATION. An operator workstation is provided with the following type

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of displays
! Graphic displays
! Alarm displays
! Trend displays

Process alarms and events which originate at DPU are placed for use in the
system and also on to the maxHistory Server for storage and analysis.
Other alarms and events originating within maxSTATION are provided to the
system by local status server of maxSTATION for reporting and archiving.
For diagnostic purpose following types of alarms are provided
! Station Alarms
- maxSTATION
- Remote Processing Units, DPU, I/O
! Network Alarms
- maxNET Alarms (e.g. Ethernet card failures, cable breaks or failed
target station)

Engineer's workstation is used for creating and maintaining configuration and

process control documentation using the maxTOOLS4E configurator software
and for creating and maintaining custom graphic displays. maxTOOLS4E
configurator performs the following functions:
! Identify and assign Distributed Processing Units , I/O modules ,and
I/O signals in the Remote Processing Unit(RPU)
! Identify cabinet layout and placement of the above RPU components as
well as power supplies , and other customer hardware
! Configure and assign Hierarchical Groups
! Configure Points
! Create configuration reports

5.0 OPERATING MODES :

In addition to the normal automatic mode of operation of the sub-group, the

following two modes are also available :

Step-by-step-mode: In this mode, all the criteria for a particular step are
simulated manually through the OWS and the command is issued
automatically. This is helpful in case a criteria is actually fulfilled but the signal is
not available to the sub-group because of a faulty transmitter.

Operator guide mode : In this mode, the sub-group only receives data from the
plant and the control stations, but the output commands are blocked. The
commands have to be issued manually from OWS. This mode is useful during
commissioning and for operator training.

These modes can be selected from OWS, whenever desired.

6.0 ATRS STRUCTURE & DESCRIPTION OF SYSTEM:

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ATRS is organised in three subgroup controls. These groups, in conjunction

with the turbine governing system, Turbine Stress Evaluator/Controller
(TSE/TSC) accomplish the various functions. The tasks assigned to each subgroup
control are described below for a typical project. Actual logics may however vary
from project to project.

6.1 Subgroup Control (SGC) Turbine :

SGC Turbine acts directly on the following systems :

1. Subloop Control (SLC) Drains.

2. Warm up Controller.
3. Starting Device of turbine governing system.
4. Speed & Load Setpoint devices of turbine governing system.
5. Auto-synchroniser.

SGC Turbine executes the following tasks, when switched ON. The operator
manually switches on the SGC program at an appropriate time for running the
turbine. The program takes off only after all the 'Release Criteria' are fulfilled.

6.1.1 Steam & metal Temperature matching:

The matching of steam & metal temperatures is an extremely important task

before admitting the steam into the turbine for the purpose of warming up the
various elements, speeding and subsequent loading. The ATRS accomplishes
these tasks effectively and efficiently. Function generators are used to determine
the desired level of temperature based on the actual metal temperature of the
critical component (X- curves).

6.1.2 Warming-up:

ATRS acts on the warmup controller to ensure a safe rate warmup of the ESV &
CV of HP turbine as permitted by the TSE. In the warmup stage, the operation of
the turbine drains is equally important and all the drains are hooked up in a sub-
loop control (SLC). Depending on the relative importance and significance of
various drain valves, the criterion for opening/closing of each individual drain valve
is defined and suitable logic built in to ensure safe operation. After the warming up
of ESV & CV of the HP turbine, the ATRS admits steam into the turbine for rolling
the turbine.

6.1.3 After ensuring adequate level of warming up and availability of all important
criterion, the ATRS takes the turbine from the barring speed to the first hold speed
which is approx. 20% of the rated speed. During the process of raising the
speed, the acceleration is controlled by the TSE so that the components do not
get overstressed. The ATRS ensure a definite hold for soaking of turbine internal
at this speed for a specified period if the HP metal temperature is less than 250
°C, otherwise the hold period is determined by the time it takes for temperature
margins of the TSE to be within permissible limits.

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6.1.4 After proper and adequate thermal soaking of the components, the ATRS raises the
speed of the TG set to rated speed. For this period also, the acceleration is
controlled by TSE except for the region where rotors cross the critical speed zone.
ATRS again ensures soaking as per process requirement and availability of margins.

6.1.5 After attaining a speed above 2950 rpm and when sufficient temperature are
available, the auto-synchroniser takes over and matches the turbine speed to a
value matching with the grid frequency. It simultaneously acts on the
Automatic Voltage Regulator (AVR) for matching the grid and generator voltages.
Auto-synchroniser synchronises the set at the right moment depending on the
frequency and phase angle. EHG immediately enables the set to take 10% load.

6.1.6 ATRS switches on the tracking device, which tracks the hydraulic controller to the
output of the electro-hydraulic controller with a set margin.

6.1.7 It facilitates the shutdown of the set in a proper sequence and switches on the
SLC drains according to the process requirement.

6.2 Sub-Group Control (SGC) - Oil Supply:

SGC oil supply directly acts on the following system :

1. Subloop control (SLC) turning gear.
2. SLC auxiliary oil pump 1.
3. SLC auxiliary oil pump 2.
4. SLC emergency oil pump.
5. SLC jacking oil pump.

SGC oil supply performs the tasks as described in the subsequent paragraphs and
simultaneously prepares the oil system to meet the situational demands of the
main set by employing the technique of recycling.

6.2.1 Auxiliary oil pump no. 1 is switched on as first step to provide the lubricating and
control fluid at the required ends.

6.2.2 The program switches on the oil temperature controller. The oil temperature
controller provides an analog control to maintain the oil temperature in the
header supplying oil to the bearings. The controller actuates a three-way valve
thereby controlling the quantity of oil being cooled in the oil cooler and the quantity
of oil being taken directly from the tank to the header.

The program only switches on the temperature controller and does not check back
the actual oil temperature for the reason that all operations on the lub. oil system
can be performed even if the oil temperature is not at the desired level. However,
the availability of oil at the desired level of temperature is important for the actual
rolling and therefore the oil temperature is checked as the "Enabling Criteria" in
the program before turbine is rolled.

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6.2.3 SGC lub. oil supply system ensures the supply of motive oil to the hydraulic turbine
of turning gear as the SLC turning gear is switched "ON" by the SGC supply. The
SLC logic is such that it opens the gate valve supplying oil to the turning gear
whenever the turbine speed is less than 200 rpm. Therefore while starting the
turbine from the standstill condition or during coasting down, the oil supply to the
turning gear is ensured. The oil supply to the turning gear is switched ‘Off’ when
turbine speed exceeds 250 rpm or SLC turning gear is switched "Off". Since the
requirements for the turning of the turbine can arise at any point of time during
operation, the operation of the turning gear valve is hooked up in SLC mode.

6.2.4 The jacking oil pumps are also hooked up in SLC mode and SGC oil supply
system switches on this SLC for jacking oil pump.

In case the turbine speed is below 510 rpm or falls below this value while
coasting down, the JOP 1 gets switched "On". In case JOP 1 does not develop
the desired amount of pressure, the command for starting JOP 2 is issued with a
time lag of 5 secs. As soon as the turbine crosses 540 rpm, the JOP 1 gets
switched off as per the logic of the SLC. However, JOP 2, if in service, will not get
switched off as per SLC logic and operator would have to switch off the JOP 2.

6.2.5 SGC lub. oil supply also switches on the SLCs for auxiliary oil pumps 1 & 2,
emergency oil pump (DC) so as to keep all the vital pumps ready for action, should
an emergency arise or develop at any stage of the process.

6.2.6 If the turbine trips after attaining a speed of more than 540 rpm, the program is
designed in such a manner so as to perform the tasks stated in para 8.2.3, 8.2.4 &
8.2.5. Similarly, if the turbine trips after the turbine attains 3000 rpm, the
whole program of oil supply is recycled to ensure the turning of the turbine.

6.2.7 Shut down program of oil supply can only be started if HP casing temperature, both
top and bottom is below 100 °C, as otherwise an inadvertent switching off could
lead to the situation of no turning operation even when the turbine is hot.

All the vital pumps are switched off after the turbine comes to standstill position.

6.3 Sub-Group Control (SGC) - Condensate & Evacuation :

SGC condensate & evacuation acts directly on the following systems:

1. Sub-loop Control (SLC) condensate extraction pumps.

2. Starting ejector, if provided.
3. Main ejectors / vacuum pumps (as applicable).
4. Vacuum breaker.

The condensate pumps are hooked up in a SLC and the SGC switches on this SLC in
step 01. The preselected pump is switched on by the SLC. If the pump which is
running is not giving the required pressure, the other pump is switched on. Also, if
"Main Steam Flow > 60%", both condensate pumps are switched "On".

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Although 'SLC Drains' is primarily hooked up with 'SGC - Turbine', 'SGC -

Condensate & Evacuation' also switches it on.

6.3.3 Before starting the evacuation process, the vacuum breaker valve is first closed
and the seal steam supply valve is also closed. Gland Steam Controller is put on
manual so that it is not able to open the seal steam supply valve.

6.3.4 If provided, the starting ejector is put into operation by opening the air isolating
valves.

6.3.5 After checking that the starting ejector valves are open, the main ejectors are
also put into operation by opening the isolating valves. However, if vacuum pumps
are provided, both the pumps are switched on.

6.3.6 The gland steam controller is put on 'auto' after checking that the turbine is on
barring and the condenser pressure is less than a preset value. The gland steam
controller brings the pressure in the gland steam header to normal, while evacuation
is in progress.

6.3.7 After the condenser pressure falls below 260 mbar, the starting ejector, if
provided, is put out of operation as it is not effective after that.

6.3.8 The main ejectors/ vacuum pumps continue the task of pulling the vacuum until
absolute pressure in condenser has reduced below 120 mbar and generator load is
>5%. After these criteria are achieved, the preselected main ejector / vacuum
pump continues running while the other one is stopped and acts as a standby.

6.3.9 In case condenser pressure again rises above 120 mbar, the standby vacuum
pump/ejector is again put into operation.

6.3.10 The shutdown program can be initiated by the operator if the release conditions
are present. Initially, all the ejectors / vacuum pumps are put out of operation.
Then the vacuum breaker valve is opened to break the vacuum. Finally the SLC
condensate pumps and the CEPs are switched off.

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